System and method for incorporating graphics into absorbent articles

Abstract

A method for incorporating graphics into absorbent articles. The method involving: providing a moving substrate to a print cylinder; sensing a line speed reference signal from a line speed target machinery component; rotating the print cylinder at a predetermined speed, based on the line speed reference signal, to thereby print a series of graphics on the moving substrate at a predetermined distance frequency; sensing a phase difference signal from a phase target machinery component; and setting an actual print cylinder phase angle, based on the phase difference signal, to approximate a predetermined phase angle to thereby position the series of graphics on the moving substrate at a series of desired graphics locations. A system for executing the method and garments produced from the method and system are also provided.

1. A system for incorporating graphics into absorbent articles, the system comprising:
 a substrate web path adapted to provide a moving substrate to a print cylinder 
 a line speed reference signal sensor associated with a line speed target machinery component comprising the main drive and adapted to generate a line speed reference signal, said line speed reference signal sensor comprising an encoder that measures the angular velocity of the main drive; 
 a phase difference signal sensor associated with a phase target machinery component and adapted to generate a phase difference signal; and 
 a printer controller adapted to operate the print cylinder at a predetermined speed based on the line speed reference signal, to thereby print a series of graphics on the moving substrate at predetermined distance frequency; 
 the printer controller being further adapted to set an actual print cylinder phase angle, based on the phase difference signal, to approximate a predetermined phase angle to thereby position the series of graphics on the moving substrate at a series of desired graphics locations. 
 
     
     
       2. The system of  claim 1 , wherein the moving substrate comprises a backsheet web. 
     
     
       3. The system of  claim 2 , wherein the system further comprises:
 an absorbent pad supply path adapted to convey an absorbent pad supply; 
 a topsheet web path adapted to provide a topsheet web; 
 a sealer adapted to join the topsheet web to the backsheet web with the absorbent pads located therebetween to thereby form an absorbent core assembly; and 
 a cutter adapted to cut the absorbent core assembly at a series of cuts; 
 wherein the phase target machinery component comprises the cutter. 
 
     
     
       4. The system of  claim 1 , wherein the phase target machinery component comprises a cutter. 
     
     
       5. The system of  claim 1 , wherein the line speed target machinery component and the phase target machinery component comprise different machinery components. 
     
     
       6. The system of  claim 1 , wherein the line speed target machinery component and the phase target machinery component comprise the same machinery component. 
     
     
       7. The system of  claim 1 , wherein the phase difference signal sensor comprises an inductance sensor. 
     
     
       8. The system of  claim 1 , wherein the series of graphics comprises a series of wetness indicators. 
     
     
       9. The system of  claim 1 , wherein the series of graphics comprises a series of combined wetness indicators and decorative graphics. 
     
     
       10. The system of  claim 1 , wherein the print cylinder comprises a flexographic print cylinder. 
     
     
       11. The system of  claim 1 , wherein the system further comprises:
 a second print cylinder, wherein the substrate web path is adapted to provide the moving substrate to the second print cylinder; and 
 wherein the printer controller is further adapted to rotate the second print cylinder at the predetermined speed, to thereby print a second series of graphics on the moving substrate at the predetermined distance frequency. 
 
     
     
       12. The system of  claim 11 , wherein the series of graphics comprises a series of wetness indicators and the second series of graphics comprises a series of decorative graphics. 
     
     
       13. The system of  claim 1 , wherein the printer controller is further adapted to detect a shutdown mode from the line speed reference signal, disengage the print cylinder from the substrate, and rotate the print cylinder at an idle speed. 
     
     
       14. The system of  claim 1 , wherein the printer controller is further adapted to detect a startup mode from the line speed reference signal, accelerate the print cylinder from an idle speed to the predetermined speed, and engage the print cylinder with the moving substrate. 
     
     
       15. The system of  claim 1 , wherein the substrate with the series of graphics printed thereon is incorporated into an absorbent article, the absorbent article being selected from the group consisting of a baby diaper, a baby training pant, and an adult incontinence article. 
     
     
       16. A system for incorporating graphics into absorbent articles, the system comprising:
 a substrate web path adapted to provide a moving substrate to a graphic applicator; 
 a line speed reference signal sensor associated with a line speed target machinery component comprising the main drive and adapted to generate a line speed reference signal, said line speed reference signal sensor comprising an encoder that measures the angular velocity of the main drive; 
 a phase difference signal sensor associated with a phase target machinery component and adapted to generate a phase difference signal; and 
 a graphic applicator controller adapted to operate the graphic applicator at a predetermined speed, based on the line speed reference signal, to thereby apply a series of graphics on the moving substrate at a predetermined distance frequency; 
 the graphic applicator controller being further adapted to set an actual graphic applicator phase angle, based on the phase difference signal, to approximate a predetermined phase angle to thereby position the series of graphics on the moving substrate at a series of desired graphics locations. 
 
     
     
       17. The system of  claim 16 , wherein the moving substrate comprises a backsheet web. 
     
     
       18. The system of  claim 17 , wherein the system further comprises:
 an absorbent pad supply path adapted to convey an absorbent pad supply; 
 a topsheet web path adapted to provide a topsheet web; 
 a sealer adapted to join the topsheet web to the backsheet web with the absorbent pads located therebetween to thereby form an absorbent core assembly; and 
 a cutter adapted to cut the absorbent core assembly at a series of cuts; 
 wherein the phase target machinery component comprises the cutter. 
 
     
     
       19. The system of  claim 16 , wherein the phase target machinery component comprises a cutter. 
     
     
       20. The system of  claim 16 , wherein the line speed target machinery component and the phase target machinery component comprise different machinery components. 
     
     
       21. The system of  claim 16 , wherein the line speed target machinery component and the phase target machinery component comprise the same machinery component. 
     
     
       22. The system of  claim 16 , wherein the phase difference signal sensor comprises an inductance sensor. 
     
     
       23. The system of  claim 16 , wherein the series of graphics comprises a series of wetness indicators. 
     
     
       24. The system of  claim 16 , wherein the series of graphics comprises a series of combined wetness indicators and decorative graphics. 
     
     
       25. The system of  claim 16 , wherein the graphic applicator is a cut-and-space device. 
     
     
       26. The system of  claim 16 , wherein the graphic applicator controller is further adapted to detect a shutdown mode from the line speed reference signal, and disengage the graphic applicator from the substrate. 
     
     
       27. The system of  claim 16 , wherein the graphic applicator controller is further adapted to detect a startup mode from the line speed reference signal, accelerate the graphic applicator to the predetermined speed, and engage the graphic applicator with the moving substrate. 
     
     
       28. The system of  claim 16 , wherein the substrate with the series of graphics applied thereto is incorporated into an absorbent article, the absorbent article being selected from the group consisting of a baby diaper, a baby training pant, and an adult incontinence article.